How I Modeled The Knight Bus from Harry Potter and The Prisoner Of Azkeban

Using Wood Carving, Vacuum Forming, Plastic Shaping, Painting, Special Building Jigs, Model‑Making and Custom Appliques

making the knight bus

Chapter 4: The Windows, Wheel Wells and Grille

From the previous chapter:
There was no drivers side indentation worth mentioning. But, the body shape is formed!

Since I was feeling listless, I felt I needed some quick satisfaction. So I started to work on the details that would allow me to vacuum form over a pattern that contained the outlines of the windows, wheel wells and grille.

I fitted the vacuum formed body shape over the wood pattern and cut out the windows. I built a little work prop that would hold up the plastic covered pattern so that I could work on the plastic — well, almost comfortably.

making the knight bus

I found an architectural template that had the correct shape for the windows. I ran a dissection needle (discarded from a kid’s microscope set) around the inside of the template to score a line. It was then easy to pick out the window. Again, I am planning to form over this window pattern to give me a nice line to paint up to.

Here’s a little further on:

making the knight bus

The photo above also shows the wheel well shapes. When I form over these shapes I will use these as a guide for cutting out the openings.

making the knight bus

I also cut out and shaped the front grille — The top part of the above photo above shows the reference pic. I used a piece of .040” styrene cut and sanded to shape.

making the knight bus

Here’s a test shot to see if my “window” concept worked. I planned on simply dumping some paint, letting the slight raised pattern guide the paint... well, this part of it worked! It looked good.

making the knight bus

To be clear, in this chapter I described the creation of a plastic pattern (A) that I will place over the original wood pattern (B) to vacuum form a shape (C) with more details than the wooden pattern alone.

Next — Chapter 5: The Driver's Indentation

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